Thin film semiconductor and method for manufacturing the same, semiconductor device and method for manufacturing the same

ABSTRACT

The present invention is related to a thin film semiconductor which can be regarded as substantially a single crystal and a semiconductor device comprising an active layer formed by the thin film semiconductor. At least a concave or convex pattern is formed intentionally on a insulating film provided in contact with the lower surface of an amorphous silicon film, whereby at least a site is formed in which a metal element for accelerating crystallization can be segregated. Therefore, a crystal nuclei is selectively formed in a portion where the concave or convex pattern is located, which carries out controlling a crystal diameter. Thus, a crystalline silicon film is obtained. A crystallinity of the crystalline silicon film is improved by the irradiation of a laser light or an intense light having an energy equivalent to that of the laser light, whereby a monodomain region in which no grain boundary substantially exit is formed.

This is a divisional of U.S. application Ser. No. 08/802,675, filed Feb.19, 1997, now U.S. Pat. No. 5,893,730.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a thin film semiconductor having aregion which can be regarded as substantially a single crystal(hereinafter referred to as "a monodomain region"), and is formed on asubstrate having an insulating surface, and to a semiconductor deviceusing the thin film semiconductor as an active layer. More particularly,the present invention relates to a thin film transistor having an activelayer constituted by a crystalline silicon film.

2. Description of the Related Art

In recent years, a technique for constituting a thin film transistor(TFT) by using a thin film silicon film (having a thickness of fromseveral hundred to several thousand of angstroms (Å)) formed on asubstrate having an insulating surface has drawn a considerableattention. A thin film transistor is widely applied to electronicdevices such as ICs and liquid crystal display devices.

The most important portion of a thin film transistor is, so to speak theheart of thin film transistor, a channel forming region and a junctionportion to join the channel forming region with the source/drain region.That is, the active layer has the greatest influence on the performanceof a thin film transistor.

As a thin film semiconductor constituting the active layer of the thinfilm transistor, generally employed is an amorphous silicon film formedby plasma CVD or low pressure thermal CVD.

A thin film transistor using an amorphous silicon film is practicallyavailable at present, however, in case higher speed operation isrequired, a thin film transistor based on thin film silicon having goodcrystallinity (hereinafter referred to as "crystalline silicon film")must be employed.

For instance, in an active matrix type liquid crystal display device orin a passive type liquid crystal display device, a drive circuit fordriving pixel TFTs provided to the pixel region, a circuit for handlingimage signals, and a memory circuit for recording various types ofinformation, are necessary for the peripheral circuits.

Moreover, in the circuits above, the circuit for processing andcontrolling the image signals and the memory circuits for recordingvarious types of information are required to have a well performancecomparable to that of a known integrated circuit using a single crystalwafer. Accordingly, in case that the above-mentioned circuits are to beintegrated by using a thin film semiconductor formed on the substrate, acrystalline silicon film having high crystallinity comparable to that ofa single crystal must be formed on the substrate.

As methods for forming a crystalline silicon film on a substrate, knownare the techniques disclosed in Japanese Laid-Open Applications 6-232059and 6-244103 filed by the present inventors. The technique disclosed inthe references above comprises forming a crystalline silicon film havingexcellent crystallinity by utilizing a metallic element capable ofaccelerating the crystallization of silicon in case of applying heattreatment at 550° C. for about 4 hours.

However, even if the technique mentioned above is employed in the activelayer of a thin film transistor, the resulting thin film transistor isstill unsatisfactory when used as a transistor constituting varioustypes of arithmetic circuit, memory circuit, or the like, because thecrystallinity thereof as an active layer is yet insufficient to sufficethe required characteristics.

In particular, it is required that the crystalline silicon film having acrystallinity comparable to that of a single crystal is substantiallyfree of crystal grain boundaries. This is because the grain boundariesfunction as an energy barrier which obstructs the path of electronswhich pass to and fro between the crystals.

The present inventors have classified the crystal growth process intofour steps. i.e., from a first to fourth step described below when theabove technique is employed. The explanation is given with reference toFIGS. 3(A) to 3(F).

Referring to FIG. 3(A), a silicon oxide film 301 is formed as a bufferlayer on the surface of a substrate. An amorphous silicon film 303 isformed thereon. The concave or convex portion 302 (only the convexportion is shown in the figure) is formed by the surface roughness or adust that was present on the surface of the silicon oxide film.

A solution containing a metallic element that accelerates thecrystallization is provided dropwise to the surface of the amorphousfilm 303, and is applied by spin coating. Thus is obtained a state as isshown in FIG. 3(A), in which a nickel layer 304 is retained on thesurface of the amorphous silicon film 303.

The amorphous silicon film 303 is crystallized thereafter by applyingheat treatment in the temperature range of from 500 to 700° C. However,in case a glass substrate is used, the heat treatment is preferablyeffected at a temperature of 650° C. or lower by taking the heatresistance of the glass substrate into consideration.

Then, as is indicated by an arrow in FIG. 3(B), the metallic elementundergoes an isotropic internal diffusion inside the amorphous siliconfilm 303 as to reach the interface with the silicon oxide film 301. Thisis a first step.

The metallic element then segregates in the concave or convex portion302 after migration inside the interface between the silicon oxide film301 and the amorphous silicon film 303. This is a second step. Thisoccurs because the metallic element seeks for an energetically stablesite, and hence, in this case, the concave or convex portion 302provides the segregation site (FIG. 3(C)).

Thus, crystal nuclei generates in the concave or convex portion 302which functions as the segregation site, because the metallic element ispresent at a high concentration. In case that the metallic element isnickel, according to the study of the present inventors, crystal nucleigenerates when the concentration of nickel is 1×10²⁰ atoms/cm³ orhigher.

Crystal growth initiates from the crystal nuclei. At first,crystallization proceeds in the direction approximately vertical to thesurface of the silicon film. This is a third step (FIG. 3(D)).

In the region 305 where crystallization proceeded in a directionapproximately vertical to the surface of the silicon film (hereinafterreferred to as "the vertical growth region"), the crystallizationproceeds in such a manner that the metallic element concentrated at ahigh concentration is pushed up with respect to the surface of thesilicon film. Accordingly, metallic elements are also condensed on thesurface of the amorphous silicon film 303 located at the upper side ofthe concave or convex portion 302. As a result, the vertical growthregion 305 is obtained as a region containing the metallic element at ahigh concentration as compared with the other regions.

Then, crystal growth occurs from the interface 306 of the amorphoussilicon film 303 that is in contact with the vertical growth region 305in a direction approximately in parallel with the substrate (thedirection shown with an arrow in FIG. 3(E)). This is a fourth step. Thecrystals 307 are columnar or needle-like crystals approximatelyequivalent to the film thickness of the amorphous silicon film 303(FIG.3(E)).

Because the crystals 307 grow in a direction approximately in parallelwith the substrate, the growth stop by colliding with other crystalsfaced opposed thereto. Thus, the boundary where collision occurs as isshown in FIG. 3(F) becomes the crystal grain boundary 308. The crystalregion 309 thus formed becomes a region (hereinafter referred to as "alateral growth region") having a relatively uniform crystallinity.

Thus, in the conventional crystallization morphology, since numeroussegregation sites were formed irregularly in this manner, the crystalnuclei has a high density and each crystal grain obstructs the growtheach other. As a result, diameter of the crystal grains becomes small.

That is, in case of forming the active layer of a thin film transistorusing a crystalline silicon film formed by the technique describedabove, for instance, crystal grain boundary is inevitably incorporatedinside the silicon film. Accordingly, it is practically impossible torealize a crystallinity equivalent to that of a single crystal.

The diameter of crystal grain can be increased by decreasing thegeneration density of the crystal nuclei, however, the location ofcrystal nuclei depends on the segregation site of the metallic element.According to the conventional technique, the sites (for instance, theconcave or convex portion 302 shown in FIG. 3(A)) which become thesegregation sites are formed irregularly, and it is impossible tocontrol the position thereof.

SUMMARY OF THE INVENTION

An object of the present invention is to form, on a substrate having aninsulating film on the surface thereof, a monodomain region having acrystallinity well equivalent to that of a single crystal. Anotherobject of the present invention is to obtain a semiconductor devicehaving an active layer constructed by using the monodomain region.

Thus, according to one aspect of the present invention, there isprovided a thin film semiconductor formed on a substrate having aninsulating film formed on the surface thereof, characterized in that:

said thin film semiconductor comprises a monodomain region which can beregarded as substantially a single crystal whose crystallinity isimproved by the irradiation of a laser light or an intense light havingan energy equivalent to that of the laser light, wherein:

said monodomain region is formed by a plurality of columnar orneedle-like crystals being aggregated approximately in parallel with thesubstrate; and

concave or convex pattern is formed intentionally on said insulatingfilm provided in contact with the lower surface of the thin filmsemiconductor.

According to another aspect of the present invention, there is provideda semiconductor device utilizing the above-mentioned monodomain regionalone as an active layer. There is a feature that substantially nocrystal grain boundaries exist inside the monodomain region.

According to still another aspect of the present invention, there isprovided a method for manufacturing a thin film semiconductor,comprising the steps of:

forming a silicon oxide film by means of sputtering on the surface of asubstrate having an insulating surface;

intentionally providing concave or convex pattern by patterning saidsilicon oxide film into a desired shape;

forming an amorphous silicon film by means of low pressure thermal CVDon said silicon oxide film;

forming a metallic element which accelerates the crystallization to saidamorphous silicon film;

crystallizing said amorphous silicon film into a crystalline siliconfilm by means of heat treatment; and

irradiating a laser light or an intense light having an energyequivalent to that of said laser light to said crystalline silicon film,

wherein: said crystalline silicon film is formed into a monodomainregion, by irradiating a laser light or an intense light having anenergy equivalent to that of said laser light. Also, it is featured thatan active layer is constituted by the monodomain region formed throughthe above steps.

The present inventors define the region obtained by the presentinvention as a region which can be regarded as substantially a singlecrystal, that is, a monodomain region. Thus, the monodomain region isdefined as a region substantially free of crystal grain boundaries, andin which hardly no crystal defects attributed to transition and stackingfaults is present.

The term "substantially free of crystal grain boundaries" signifies thatthe region is electrically inert even if a grain boundary should bepresent. Such electrically inert crystal grain boundaries include {111}twin grain boundary, {111} stacking fault, {221} twin grain boundary,{221} Twist twin grain boundary, etc. (see R. Simokawa and Y. Hayashi;Jpn. J. Appl. Phys. 27 (1987) pp. 751 to 758).

The present inventors assume with high possibility that the grainboundaries included in the monodomain region are electrically inertgrain boundaries. That is, the apparent grain boundaries are believed tobe inert regions which electrically do not hinder the movement ofcarriers.

Accordingly, the present inventors studied a means for increasing thecrystal grain diameter to reduce the grain boundaries. As a result, theyfound, for the first time, a means for controlling crystal nuclei.

The means comprises, firstly, providing an extremely smooth surfacestate to the insulating film that is in contact with the lower surfaceof the amorphous silicon film. Accordingly, a silicon oxide film formedby means of sputtering using an artificial quartz target is provided asa buffer layer under the amorphous silicon film (for reference, thecomposition of the artificial quartz target is given in FIG. 14). Thesilicon oxide film thus formed is highly dense and smooth, and containsvery few concave or convex portions which became segregation sites inconventional techniques.

Then, the silicon oxide film thus obtained is patterned to intentionallyprovide concave or convex patterns. That is, by intentionally formingsegregation sites for the metallic elements which accelerate thecrystallization, the locations of generating crystal nuclei can becontrolled.

That is, the present means has a great advantage of making it possibleto design crystals of desired size at a desired position in the stage ofdesigning the device. This is extremely advantageous from the industrialpoint of view.

The present invention is also characterized in that a low pressurethermal CVD is used for forming the amorphous silicon film. Theamorphous silicon film formed by means of low pressure thermal CVDcontains less hydrogen and is denser as compared with an amorphoussilicon film formed by plasma CVD. Hence, the amorphous silicon filmobtained in the present invention is characterized in that it containsless spontaneously formed nuclei.

Nuclei that are formed spontaneously and in large number highlyobstructs the control of crystal nuclei. Accordingly, it is veryconvenient if the number of spontaneously formed nuclei is small.

Next, means for converting large size crystals thus obtained into singlecrystals (more accurately, means for forming monodomain regions) wasstudied. As a result, it was found that monodomain regions are availableby irradiating a laser light or an intense light having an energyequivalent to that of a laser light to the thus obtained crystals.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1(A) to 1(F) are cross sectional views showing the formation stepsof a thin film semiconductor having a monodomain region;

FIGS. 2(A) to 2(C) show the constitution of monodomain region;

FIGS. 3(A) to 3(F) are cross sectional views showing the formation stepsof a thin film semiconductor having a monodomain region;

FIGS. 4(A) to 4(E) show the manufacturing process of a semiconductordevice;

FIG. 5 is an explanatory figure showing the problems of SOI technique;

FIG. 6 shows the constitution of a monodomain region;

FIG. 7 shows the active layer formed on a monodomain region;

FIGS. 8(A) to 8(E) show the manufacturing process of a semiconductordevice;

FIGS. 9(A) to 9(D) show the manufacturing process of a semiconductordevice;

FIGS. 10(A) and 10(B) show the manufacturing process of a semiconductordevice;

FIGS. 11(A) to 11(D) show the manufacturing process of a semiconductordevice;

FIGS. 12(A) and 12(B) show the constitution of a DRAM;

FIGS. 13(A) and 13(B) show the constitution of an SRAM;

FIG. 14 is a table showing the composition of an artificial quartztarget;

FIGS. 15(A) to 15(D) show the manufacturing process of a semiconductordevice; and

FIGS. 16(A) to 16(F) are explanatory figures of application products.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The constitution of the present invention is described in further detailwith reference to the embodiments below. It should be understood,however, that the present invention is not to be construed as beinglimited thereto.

EMBODIMENT 1

The present embodiment describes the formation process of a monodomainregion, which is the most important concept of the present invention.FIGS. 1(A) to 1(F) show the cross sectional view of the silicon filmformed on a substrate having an insulating surface.

Referring to FIG. 1(A), a silicon oxide film 102 is formed on a glasssubstrate 101 by sputtering. A quartz substrate or a silicon substratecan be used instead of the glass substrate. An artificial quartz targetis used for the sputtering.

The silicon oxide film 102 formed by using artificial quartz target hasan extremely flat and smooth surface. More specifically, for example,the height of the surface roughness is within 30 Å, and the widththereof is 100 Å or more. Even if AFM (Atomic Force Microscopy) shouldbe used, it is difficult to recognize as irregularities.

After forming the silicon oxide film 102, patterning is effected tointentionally form a concave or convex pattern 103. In the presentembodiment, reference is made specifically to fine island-like squarepatterns that are formed as such to intentionally obtain convexportions. However, a similar effect can be obtained by forming thepatterns as such to obtain concave portions. The concave or convexpattern 103 is provided at a height corresponding to about half the filmthickness of the amorphous silicon film that is formed hereinafter.

After performing patterning into a desired shape, an amorphous siliconfilm 104 is formed at a thickness of from 100 to 750 Å (preferably from150 to 450 Å) by means of plasma CVD, sputtering, or low pressurethermal CVD. In case low pressure thermal CVD is employed, gaseousdisilane (Si₂ H₆) or trisilane (Si₃ H₈) is used as the film depositiongas.

By controlling the film thickness of the amorphous silicon film 104 inthe range above, not only the step of converting it into a singlecrystal by the irradiation of a laser light is performed effectively,but also a semiconductor device having a low OFF current can bemanufactured by employing the thus obtained crystalline silicon film forthe active layer of the semiconductor device.

An amorphous silicon film formed by low pressure thermal CVD generatesthe spontaneously formed nuclei at a low ratio in the later step ofcrystallization. The ratio of the spontaneously formed crystal nuclei isthe ratio of generating nuclei without being influenced by the metallicelement such as nickel, which accelerates the crystallization of theamorphous silicon film.

The above effects are favorable from the viewpoint of obtaining crystalshaving large diameter in the later step of crystallization, because theratio of causing mutual interference (colliding each other to hinder thecrystal growth) among the crystals can be reduced.

In case of forming an amorphous silicon film 104, care must be taken tothe surface cleanness of the silicon oxide film 102 provided as a bufferlayer. As was described hereinbefore with reference to a conventionaltechnique, contaminations provide segregation sites for the metallicelement which accelerates the crystallization as to cause nucleation.

After the amorphous silicon film 104 is formed, an UV light isirradiated in an oxygen atmosphere to form a very thin oxide film (notshown in the figure) on the surface of the amorphous silicon film 104.The oxide film is provided in order to improve the wettability of theamorphous silicon film to the solution that is applied in the later stepof solution coating to introduce the metallic element.

Then, an aqueous film not shown in the figure is formed by dropping, onthe surface of the amorphous silicon film 104, a solution containing themetallic element for accelerating the crystallization at a predeterminedconcentration. The metallic element is one or a plurality of elementsselected from the group consisting of Fe, Co, Ni, Ru, Rh, Pd, Os, Ir,Pt, Cu, and Au, but according to the present inventors' study, Ni(nickel) was found to be most effective.

Considering the residual impurities in the later heating step, preferredis to employ a nickel nitrate solution. Although, a nickel acetatesolution is also usable, a nickel acetate solution contains carbon, andtherefore there is a fear that carbon may remain as a residue inside thefilm in the later heating step.

Referring to FIG. 1(A), spin coating is performed using a spinner toobtain a state in which a nickel layer 105 is retained on the amorphoussilicon film 104 with an oxide film (not shown in the figure) beinginterposed therebetween.

In this instant, a concave or convex portion 106 is formed in theamorphous silicon film 104 provided on the upper side of the concave orconvex pattern 103, in correspondence with the shape of the concave orconvex pattern 103. Thus, because of surface tension, the periphery ofthe concave or convex portion 106 tends to provide a region in whichnickel is locally condensed. Thus, in the later step of crystallization,it also functions effectively to facilitate a fourth step ofcrystallization (i.e., the crystallization in the directionapproximately in parallel with the substrate).

In the present embodiment, the solution coating step was performed onthe amorphous silicon film 104. However, the same effect can be obtainedby applying it on the buffer layer, i.e., the silicon oxide film 102.before forming the amorphous silicon film. Furthermore, the solution canbe applied to both surfaces of the silicon oxide film 102 and theamorphous silicon film 104.

After achieving the state illustrated in FIG. 1(A), hydrogen is removedby heating the structure at 450° C. for a duration of about 1 hour underan inert gas atmosphere. Then, the amorphous silicon film 104 iscrystallized by applying heat treatment in a temperature range of from500 to 700° C., representatively in a range of from 550 to 600° C., for4 to 8 hours. In case of forming the film on a glass substrate, however,the heat treatment is preferably performed at a temperature not higherthan 650° C. by taking the heat resistance of the glass intoconsideration. The crystallization proceeds in a manner described below.

In a first step, nickel is activated by heating and diffusesisotopically inside the amorphous silicon film 104 as is indicated bythe arrows (FIG. 1(B)).

Next, in a second step, nickel migrates at the interface between thesilicon oxide film 102 and the amorphous silicon film 104 as tosegregate in the concave or convex pattern 103. That is, the concave orconvex pattern 103 functions as an intentionally formed segregation site(FIG. 1(C)).

Then, as the nickel concentration in the segregation site, i.e., theconcave or convex pattern 103, becomes as high as about 1×10²⁰ atoms/cm³or even higher, nucleation occurs as to proceed crystallization in adirection approximately vertical to the silicon film surface. Thevertical growth region 107 that is formed in a third step is a regioncontaining nickel at a high concentration (FIG. 1(D)).

As the fourth step, crystal growth initiates from the vertical growthregion 107 above and proceeds in a direction approximately in parallelwith the silicon film surface. The lateral growth region 108 thus formedconsists of a plurality of columnar or needle-like crystals beingaggregated and relatively oriented in one direction, hence, from theviewpoint of crystallinity, this region is superior to the verticalgrowth region 107.

Because the segregation site is formed intentionally under control, thecrystal diameter can be enlarged without being influenced by othercrystal grains. That is, by properly designing the position of formingthe segregation sites, crystals of desired size can be obtained atdesired positions.

However, because the limit of crystal grain diameter depends on thetemperature and the period of time of the heat treatment, the size canbe properly determined in relation with the production cost and thelike. Furthermore, it should be taken into consideration that thecrystal growth proceeds in the later step of converting the crystal intoa single crystal.

Thus is obtained a crystalline silicon film 109 as is shown in FIG.1(F). What should be noted here is that the present invention isfundamentally different from a known technique of graphoepitaxy.

Graphoepitaxy is a technique which provides a uniform orientation to thecrystalline silicon film by rendering regular shape to the surface ofthe undercoat film, thereby utilizing the nature of the amorphoussilicon film that crystallization occurs from the most stable surface.

The present invention is characterized in that the surface morphology ofthe base film is varied to change the surface energy, and therebyproviding region in which the metallic element for accelerating thecrystallization is easily segregated. Accordingly, the present inventiondiffers from the technique of graphoepitaxy in which the surfacemorphology is changed for the formation of crystal nuclei.

FIG. 2(A) shows the planar view of the crystalline silicon film 109viewed from the upper side. Referring to FIG. 2(A), a vertical growthregion 201 (corresponding to the region 107 in FIG. 1(D)) formed in thethird step exhibits square fine island like pattern in the presentembodiment. A lateral growth region 202 (corresponding to the region 109in FIG. 1(F)) formed in the fourth step grows from a nuclei provided asthe vertical growth region 201 at the center. Because the verticalgrowth region 201 in the present embodiment can be regarded as points,the lateral growth region 202 is obtained in an approximately hexagonalshape.

The reason why the lateral growth region exhibits a hexagonal shape canbe explained as follows. Considering the crystal morphology of a siliconfilm, it is known that, in general, a nucleus surrounded by (111)surfaces grow into a crystal grain with a hexagonal shape.

In the present embodiment, nickel is used as the metal element foraccelerating the crystallization. The present inventors have shown thatnickel silicide is formed on the front edge portions and on the sidesurface portions of the columnar or needle-like crystals during thecrystallization.

It is also known that (111) surface is the stable surface of nickelsilicide. By taking this fact into consideration, it can be understoodthat the vertical growth region 301, which is the crystal nucleus, issurrounded dominantly by the (111) surface, i.e., the stable surface ofthe nickel silicide.

Thus, it can be readily understood that the lateral growth region 202grown from a point, i.e., the vertical growth region 201, is shaped intoan approximately hexagonal morphology by the crystal growth in a fourthstep.

The lateral growth region 202 formed in the manner described above canbe divided into six portions A to F as shown in FIG. 2(A). In thisinstance, the six portions A to F are apparently individual crystalgrains. This is because defects such as slips are formed in the regionat which the portions A to F collide with each other, and crystal grainboundary is thereby formed.

FIG. 2(B) shows a simplified view of an enlarged single portion takenfrom the regions A to F. Referring to FIG. 2(B), the regions A to F areeach formed by an aggregation of a plurality of columnar or needle-likecrystals. Hence, macroscopically, the regions each appear as singlecrystal grains because the crystals are densely aggregated.

The columnar or needle-like crystals are each monodomains substantiallyfree of internal grain boundary.

Furthermore, because each of the crystals grow by eliminating theimpurity elements such as nickel from the inside, metal silicides areformed on the surface of the crystals. Thus, as is shown in FIG. 2(B), ametal element, i.e., nickel, is segregated in the grain boundary 203.

Hence, the state illustrated in FIG. 2(B) shows that a plurality ofmonodomains are gathered to provide a region with a relatively improvedcrystallinity, but that the regions A to F do not form a singlemonodomain region.

To implement the present invention, an additional step for improving thecrystallinity of the lateral growth region 202 is necessary. In thepresent invention, this step is specially denoted as a "step for singlecrystal formation".

The step for single crystal formation according to the present inventionspecifically comprises irradiating a laser light or an intense lighthaving an energy equivalent thereto to the thus obtained crystallinesilicon film.

Preferably, an excimer laser emitting a laser light in the ultravioletregion is used for the above purpose. More specifically, usable are KrFexcimer laser (248 nm in wavelength), XeCl excimer laser (308 nm inwavelength), etc. Otherwise, an intense light using an ultraviolet raylamp may be used to obtain the same effect.

When the crystalline silicon film is irradiated with the laser light,the irradiated surface is locally heated to a high temperature toinstantaneously acquire a molten state. As is shown in FIG. 2(B),however, in practice, metal silicide that is segregated in the grainboundary portion 203 of the columnar or needle-like crystalspreferentially undergo melting, and the columnar or needle-like crystalsdo not easily undergo melting.

That is, in case a laser light is irradiated to a lateral growth regioncomprising the constitution shown in FIG. 2(B), the grain boundary 203preferentially, but temporarily, undergo melting, and thenrecrystallizes. Referring to FIG. 2(C), the joint interface that isformed by the temporal dissociation and recombination of the grainboundary 203 in FIG. 2(B) is shown by broken lines 204.

In that instance, the silicon lattice in the vicinity of the grainboundary 203 rearranges as to undergo recombination in such a mannerthat silicon atoms are well matched. Thus, a plurality of columnar orneedle-like crystals that were aggregated inside the individual regionsof A to F as shown in FIG. 2(B) comprise substantially no grainboundaries as shown in FIG. 2(C).

Moreover, because the crystal defects such as dislocations and stackingfaults that were present inside the needle-like or columnar crystalsmostly diminish, the crystallinity of the portions which were initiallythe columnar or needle-like crystals also becomes considerably improved.

In this instance, the volume of each of the regions A to F expands dueto the rearrangement of the silicon lattice. As a result, the siliconfilm is observed to undergo elevation at the grain boundaries (i.e., theouter peripheral portions of the monodomain regions) shown in FIG. 2(A),at which the regions A to F collide with each other. The elevation ofthe silicon film is characteristic to the case when laser irradiationtreatment is performed.

In case the elevation of silicon film occurs at the grain boundaries, itis phenomenologically known that high intracrystalline crystallinity isachieved, but the reason for this is not yet well established.

Furthermore, in case an amorphous silicon film 500 Å in thickness isused, for instance, SEM observation revealed that the elevation ofsilicon film is known to be about 500 Å.

The crystalline silicon film thus formed through the aforementionedprocess steps yields a monodomain region with a highly improvedcrystallinity equivalent to that of a single crystal.

Another constitution of the present invention comprises forming anactive layer of a semiconductor device represented by a thin filmtransistor, utilizing the aforementioned monodomain region alone.

In manufacturing an active-matrix type liquid crystal display device,FIG. 7 shows an active layer 24 provided in a matrix-like arrangement ona substrate 21 having an insulating surface.

Referring to FIG. 7, the portion in which a vertical growth region waspresent is shown by broken lines 22. The portion 23 in which grainboundary was formed by the collision of lateral growth regions is shownby dotted lines, because it cannot be observed after the active layer 24is formed.

As is shown in FIG. 7, the active layer 24 of the thin film transistoris formed in a matrix-like pattern in such a manner that the verticalgrowth region and the grain boundary may not be included in the activelayer.

FIG. 7 shows a local view, but the same holds true to the entire activelayer that is formed on the substrate 21. That is, the active lay s forthe several millions of thin transistors are formed by utilizing onlythe monodomain region free of grain boundaries.

EMBODIMENT 2

The present embodiment refers to a constitution similar to thatdescribed in Embodiment 1, except that the irradiation of a laser lightis replaced by the same of an intense light having an energy equivalentto that of the laser light. RTA (rapid thermal annealing) is known as atechnique for implementing the constitution of the present embodiment.

RTA is a method which comprises irradiating an intense light such as aninfrared light or an ultraviolet light to the object by using a lamp,etc. The method is characterized in that the treatment can be completedin a short period of time of about several to several tens of seconds,and it can be conducted at a high heating and cooling rates. Thus, thethin film on the outermost surface alone can be heated. Morespecifically, for instance, only the thin film formed on the surface ofa glass substrate can be annealed at an extremely high temperature ofabout 1,000° C.

In this method, the throughput also can be considerably increased in theproduction process, because the period of time of treatment is short.Accordingly, this method is a very effective means from the viewpoint ofincreasing productivity.

EMBODIMENT 3

The present embodiment refers to a constitution in which an active layerof a thin film transistor is constructed by using a monodomain regionobtained in the process steps described in Embodiment 1. Although a topgate type constitution is described in the present embodiment, it isalso possible to apply the constitution to a bottom gate type.

Referring to FIG. 4(A), a thin film semiconductor comprising amonodomain region is formed in accordance with the process stepsdescribed in Embodiment 1, and is patterned to form an active layer 403consisting of monodomain region alone. Similarly, as is described inEmbodiment 1, reference numeral 401 is a glass substrate and referencenumeral 402 is a silicon oxide film.

Then, a 1,500 Å thick silicon oxide film 404 which functions as a gateinsulating film is formed by plasma CVD. A silicon oxynitride film or asilicon nitride film may be used in the place of the silicon oxide film.

A 5,000-Å-thick aluminum film 405 is formed by sputtering thereafter toprovide a gate electrode. Scandium is added at a concentration of 0.2%by weight into the aluminum film 405. Other metals such as tantalum ormolybdenum can be used in place of aluminum. Thus is obtained a state asis shown in FIG. 4(A).

After forming the aluminum film 405, an extremely thin anodic oxide film(not shown in the figure) is formed. The anodic oxide film is formed byusing an ethylene glycol solution containing 3% of tartaric acidneutralized by ammonia water as the electrolytic solution. Thus, anodicoxidation is performed in the electrolytic solution using the aluminumfilm 405 as the anode and platinum as a cathode.

The anodic oxide film that is formed in this step is dense, and itfunctions to tightly bring the resist mask, which is formed later, intocontact with the aluminum film. In the present embodiment, the anodicoxide film not shown in the figure is formed at a thickness of about 100Å. The film thickness can be controlled by the applied voltage.

The aluminum film 405 is patterned thereafter to form an island-likealuminum film pattern 406 which provides the base of the gate electrode409. The resist mask (not shown in the figure) used in this step is leftover as it is (FIG. 4(B)).

Once the state shown in FIG. 4(B) is attained, anodic oxidation isperformed again by utilizing the aluminum film pattern 406 as the anode.An aqueous 3% oxalic acid solution is used as the electrolytic solutionin this case. In this step of anodic oxidation, oxidation proceeds onlyon the side surface of the aluminum film pattern 406 because the resistmask not shown in the figure is still present. Thus, an anodic oxidefilm 407 is formed as is shown in FIG. 4(C).

The anodic oxide film 407 thus obtained in the present step is porous,and it may be grown to a thickness of several micrometers.

In the present embodiment, however, the porous anodic film 407 is formedat a thickness of 7,000 Å by controlling the period of time of anodicoxidation.

After the formation of the porous anodic oxide film 407 as is shown inFIG. 4(C), the resist mask not shown in the figure is removed. Then,another dense anodic oxide film 408 is formed by performing the anodicoxidation again under the same conditions as those employed in theprevious step of forming a dense anodic oxide film. However, the anodicoxide film 408 is formed at a thickness of 800 Å.

In this step, the anodic oxide film 408 is formed as is shown in FIG.4(C) because the electrolytic solution penetrates into the porous anodicoxide film 407.

If the anodic oxide film 408 is formed thickly at a thickness of 1,500 Åor more, an offset gate region can be formed in the later step ofimplanting impurity ions.

The dense anodic oxide film 408 functions in such a manner to preventhillocks from generating in the later steps on the surface of the gateelectrode 409.

Subsequent to the formation of the dense anodic oxide film 408, impurityions are implanted to form source/drain regions. In the present stage, Pions are implanted to form an N-channel type thin film transistor.

Thus are obtained a source region 410 and a drain region 411 into whichimpurity is added at a high concentration (FIG. 4(C)).

After selectively removing the porous anodic oxide film 407 by using amixed acid of acetic acid, phosphoric acid, and nitric acid, P ions areimplanted again, but at a dose lower than that used previously for theformation of source/drain regions 410 and 411.

In this manner, low impurity density regions 412 and 413 containingimpurities at a density lower than that of the source region 410 and thedrain region 411 can be formed. The region 414 is formed in aself-aligning manner as a channel forming region (FIG. 4(D)).

Subsequent to the step of implanting impurity ions, a laser light, aninfrared light, or an ultraviolet light is irradiated to anneal theregion into which ions are implanted.

Thus are formed the source region 410, the low density impurity region412, the channel forming region 414, the low density impurity region413, and the drain region 411. The low density impurity region 413 isthe commonly known LDD (lightly doped drain) region.

It is effective to then perform plasma hydrogenation treatment at atemperature in a range of from 300 to 350° C. for a period of time offrom 0.5 to 1 hour. By conducting this treatment step, hydrogen can beadded into the active layer 403 at a concentration of 5% by atomic(1×10²¹ atoms/cm³) or lower, i.e. from 1×10¹⁵ to 1×10²¹ atoms/cm³.

Because hydrogen thus added into the active layer 403 is active, it canbe removed by neutralizing a dangling bond of silicon or the interfacedensity level of the active layer/gate insulating film.

After thus obtaining the state as is shown in FIG. 4(D), an interlayerinsulating film 415 is formed. The interlayer insulating film 415 isconstructed by using a silicon oxide film, or a silicon nitride film asilicon oxynitride film, a resin film, or a layered film thereof. It ispreferred to use a silicon nitride film because it prevents thepreviously added hydrogen from being re-discharged to the outside of thedevice.

Then, after forming contact holes, a source electrode 416 and a drainelectrode 417 are formed. In case a pixel TFT is formed in an activematrix type liquid crystal display, no take out electrode from the gateelectrode 409 is necessary, but in case of a circuit TFT for use in theperipheral drive circuit, the take out electrode from the gate electrode409 must be formed at the same time.

By performing heat treatment under a hydrogen atmosphere at 350° C., theentire device is hydrogenated to obtain a finished thin film transistoras is shown in FIG. 4(E).

The thin film transistor thus obtained comprises an active layerconsisting of a monodomain region. Hence, a favorable field effectmobility capable of high speed operation can be obtained. Furthermore,because no grain boundaries or segregation of nickel compounds and thelike occur in the channel region and the drain junction portions, ahighly reliable thin film transistor can be manufactured.

EMBODIMENT 4

Recently, a structure comprising a single crystal formed on a siliconsubstrate having a silicon oxide film interposed therebetween, i.e., theso-called SOI structure, is attracting much attention. As a breakthrough for a device of low energy consumption, the study on an SOIstructure is in a rapid progress.

Substantially, the monodomain region according to the present inventionhas a crystallinity well equivalent to that of a single crystal.Accordingly, it can be readily applied to a SOI technique. In thepresent invention, problems yet to be solved for an SOI substrate isconsidered in comparison with the present invention.

The problems remaining yet to be solved in the SOI technique aresummarized in FIG. 5. Referring to FIG. 5, it can be seen that theproblems include those related to crystallinity, such as the interfacedensity level in the silicon film and fixed charges, and thoseattributed to external factors, such as metallic contamination and boronconcentration.

In the present invention, a laser light or an intense light having anenergy equivalent to that of a laser light is irradiated to thecrystalline silicon film to improve the crystallinity and recombinecrystals with each other (form single crystals).

Concerning the effect of the laser annealing, factors which unfavorablyaffect the crystallinity, such as the pipe density, interface densitylevel, fixed charges, penetrating transition, etc., can be removed orconsiderably reduced.

Moreover, in case the precipitate shown in FIG. 5 is a silicide basedsubstance, it can be easily molten and evaporated at the instant thelaser light is irradiated thereto. In case it is an oxide basedsubstance, the effect of the laser light which locally elevates thetemperature as to cause the oxygen to undergo redissociation anddiffusion can be expected. Therefore, an oxide can be eliminated.

EMBODIMENT 5

The present embodiment refers to a constitution similar to thatdescribed in Embodiment 1, except that the concave or convex patternsformed on the silicon oxide film provided as the buffer layer arechanged.

Instead of the square fine island-like patterns formed in Embodiment 1,rectangular groove-like patterns are formed in the present embodiment.Although concave portions are formed in the present embodiment, the sameeffect can be obtained by forming convex portions.

The crystallization step of the amorphous silicon film is omitted herebecause it is the same as is described in Embodiment 1. The shape of thecrystal grains after the crystallization is shown in FIG. 6.

Referring to FIG. 6, lateral growth region 602 is formed from thevertical growth region 601 provided as the crystal nucleus. The presentembodiment differs from Embodiment 1 in that the crystal nucleus isregarded as a line, and not as a point.

Thus, the resulting crystal grain exhibits an approximately elongatedhexagonal shape. The lateral growth region 602 consists of eight regionsA to H. However, because the vertical growth region 601 has a length Ysufficiently longer than the width X, the regions A to C and F to Hbecomes negligibly small compared with the regions D and E when the filmis formed on a quartz substrate.

The advantage of forming the concave or convex pattern in the shapeabove is that the regions D and E become monodomain regions larger thanthose obtained in Embodiment 1. That is, by forming the active layer ofa thin film transistor by using those regions alone, a plurality ofactive layers having the same crystallinity can be formed within asingle monodomain.

EMBODIMENT 6

The present embodiment refers to a constitution in which the TFTdescribed in Embodiment 3 is used to form a CMOS structure. Themanufacturing process steps of the present embodiment are shown in FIGS.8 to 10. The crystalline silicon film formed by the present inventionhas a wide application range, and the method of forming a CMOS structureis not only limited to that described in the present embodiment.

First, in accordance with the constitution described in Embodiment 1, asilicon oxide film 32 is formed on a glass substrate 31, and acrystalline silicon film comprising a monodomain region is obtainedthereon. By patterning the thus obtained crystalline silicon film, anactive layer 33 and an active layer 34, both consisting of monodomainregion alone, are obtained for the N-channel type TFT and the P-channelTFT, respectively.

After forming the active layers 33 and 34, a silicon oxide film 35 whichfunctions as a gate insulating film is formed by means of plasma CVD.This film is formed at a thickness of from 500 to 2,000 Å,representatively, at a thickness in a range of from 1,000 to 1,500 Å.Furthermore, other insulating films such as a silicon oxynitride film ora silicon nitride film can be used as a gate insulating film in theplace of the silicon oxide film.

Thus is obtained a state as is illustrated in FIG. 8(A). To make theexplanation simple, a case of forming, a pair of N-channel type thinfilm transistor and Pchannel type thin film transistor is describedbelow. In general, a unit comprising several hundred or more ofN-channel type thin film transistors and P-channel type thin filmtransistors is formed on a single glass substrate.

After the state shown in FIG. 8(A) is obtained, an aluminum film 36which constitutes the gate electrodes 1 and 2 is formed as is shown inFIG. 8(B). Scandium is added at a concentration of 0.2% by weight intothe aluminum film to suppress the generation of hillocks and whiskers.The aluminum film can be formed by methods such as sputtering andelectron beam vapor deposition.

Hillocks and whiskers are prickle-like or needle-like protrusionsattributed to the abnormal growth of aluminum. Hillocks and whiskerscause short circuit and cross talk between the adjacent wirings or thespaced wirings.

Other anodically oxidizable metals such as tantalum can be used in placeof an aluminum film.

After an aluminum film 36 is formed, a thin, dense anodic oxide film 37is formed by performing anodic oxidation in an electrolytic solutionusing the aluminum film 36 as the anode.

In the present embodiment, an ethylene glycol solution containing 3% oftartaric acid and neutralized by ammonia is used as the electrolyticsolution. A dense anodic oxide film can be obtained by using the presentanodic oxidation method. The film thickness can be controlled by theapplied voltage.

In the present embodiment, the anodic oxide film 37 is formed at athickness of about 100 Å. The anodic oxide film 37 increases theadhesiveness to the resist mask that is formed in the later step. Thusis obtained a state as is shown in FIG. 8(B).

Then, resist masks 38 and 39 are formed. By using the resist masks 38and 39, the aluminum film 36 and the anodic oxide film 37 provided onthe surface thereof are patterned to form patterns 40 and 41 (FIG.8(C)).

Then, anodic oxidation is performed by using a 3% aqueous oxalicsolution as the electrolytic solution and the residual aluminum filmpatterns 40 and 41 as the a nodes.

In this step of anodic oxidation, the anodic oxidation proceedsselectively on the side surfaces of the residual aluminum film patterns40 and 41. This is because a dense anodic oxide film and the resistmasks 38 and 39 remain on the upper surface of the aluminum filmpatterns 40 and 41.

Porous anodic oxide films 42 and 43 are formed by the present anodicoxidation step. The porous anodic oxide films 42 and 43 m ay be formedto a thickness of about several micrometers.

In the present embodiment, the distance of progressive anodic oxidation,which corresponds to the film thickness, is 7,000 Å. The length of thelow density impurity region, which is to be established later, dependson this distance of progressive anodic oxidation. By experience, thegrowth distance of the porous anodic oxide films 42 and 43 is preferablyin a range of from 6,000 to 8,000 Å. Thus is obtained a state as isshown in FIG. 8(D).

The gate electrodes 1 and 2 are established at this stage. The resistmasks 38 and 39 are removed after the state shown in FIG. 8(D) isrealized.

Anodic oxidation is performed again by using an ethylene glycol solutioncontaining 3% of tartaric acid and neutralized by ammonia as theelectrolytic solution. In this step, the electrolytic solution intrudesinto the porous anodic oxide films 42 and 43. Dense anodic oxide films44 and 45 as are shown in FIG. 8(E) are obtained as a result.

The thickness of the dense anodic oxide films 44 and 45 is in a range offrom 500 to 4,000 Å. The film thickness thereof is controlled bychanging the duration of applying the voltage. The residual portion ofthe dense anodic oxide film 37 formed previously is integrated with theanodic oxide films 44 and 45.

Referring to FIG. 8(E), P (phosphorus) ions are doped into the entiresurface as impurity ions which render the structure N-type conductive.

The doping in this stage is effected at a high dose of 0.2-5×10¹⁵ /cm²,preferably, 1-2×10¹⁵ /cm². Plasma doping or ion doping is used for themethod.

Regions 46, 47, 48, and 49, which are heavily implanted with P ions, areformed as a result of the step shown in FIG. 8(E).

The porous anodic oxide films 42 and 43 are removed thereafter by usingan aluminum mixed acid. In this case, the active layer region positionedjust under the anodic oxide films 42 and 43 is substantially intrinsicbecause no ions are implanted therein.

Then, a resist mask 50 is formed in such a manner that the elementconstituting the P-channel type thin film transistor on the right sideis covered thereby. Thus is obtained a state shown in FIG. 9(A).

After the state shown in FIG. 9(A) is obtained, P ions are implantedagain as is shown in FIG. 9(B). The implantation of the P ions isperformed at a low dose of 0.1-5×10¹⁴ /cm², preferably, 0.3-1×10¹⁴ /cm².

That is, the dose of P ions in the implantation performed in the stepshown in FIG. 9(B) is controlled to be lower than that in theimplantation of the step shown in FIG. 8(E).

Thus, lightly doped regions 52 and 54 become the low density impurityregions. The regions 51 and 55 are the high density impurity regions inwhich P ions are implanted at a higher density.

By performing this step, the region 51 becomes the source region for theN-channel type thin film transistor. Regions 52 and 54 are the lowdensity impurity regions, and the region 55 is the drain region. Theregion 53 is a substantially intrinsic channel forming region. The lowdensity impurity region 54 is the commonly known LDD (lightly dopeddrain) region.

Although not shown specifically in the figure, the region shielded bythe anodic oxide film 44 from the ion implantation is present betweenthe channel forming region 53 and the low density impurity regions 52and 54. This region is denoted as an offset gate region, and is extendedfor a distance corresponding to the film thickness of the anodic oxidefilm 44.

The offset gate region is substantially intrinsic because no ions areimplanted therein, but it neither forms a channel because no gatevoltage is applied thereto. Thus, it functions as a resistor whichrelaxes the electric field intensity and suppresses degradation.However, it does not function as an effective offset gate region in casethe distance (the offset gate width) thereof is short. Furthermore,there is no clear boundary in the distance which tells the limit ofeffective function.

Then, the resist mask 50 is removed to form a resist mask 56 coveringthe N-channel type thin film transistor on the left side as is shown inFIG. 9(C).

Referring to FIG. 9(C), B (boron) ions are implanted as impurities whichimpart P-type conductivity. The dose of the B ions in the presentembodiment is about 0.2-10×10¹⁵ /cm², preferably, 1-2×10¹⁵ /cm². Thedose of B ions in FIG. 9(C) is higher than that of P ions in FIG. 8(E).

The regions 57 and 61 formed in the present step contain impuritieswhich impart an N-type or a P-type conductivity, but they only functionsubstantially as pads (hereinafter referred to as "contact pads") formaking contact with the take out electrodes. More specifically,differing from the N-channel type thin film transistor on the left side,the regions 57 and 61 are clearly distinguished from source/drain.

The present inventors define, with respect to the P-channel type thinfilm transistor, the region 58 as the source region and the region 60 asthe drain region.

The regions 58 and 60 are formed by implanting B ions alone into thesubstantially intrinsic region. Accordingly, because no ions other thanB is present, the impurity concentration can be easily controlled so asto realize a well-aligned PI junction. Furthermore, disordering incrystallinity attributed to ion implantation can be suppressed to arelatively low level.

An offset gate region can be formed by using the anodic oxide film 45.However, it is known by experience that the P-channel type thin filmtransistor hardly undergoes degradation. Accordingly, it is notnecessary in particular to provide an offset gate region.

A source region 58 and a drain region 60 for the P-channel type thinfilm transistor are formed in this manner. The region 59 becomes achannel forming region because no impurity in particular is implantedtherein. As is described hereinbefore, contact pads 57 and 61 areestablished to take out electric current respectively from the sourceregion 58 and the drain region 60.

Upon completion of the step shown in FIG. 9(C), the resist mask 56 isremoved to obtain the state shown in FIG. 9(D). Laser light isirradiated thereafter for the activation of the implanted impurities andfor the annealing of the regions into which the impurity ions areimplanted.

Thus, the irradiation of laser light is effected on the regions shown bythe pair of source/drain regions 51 and 55 of the N-type thin filmtransistor and the pair of source/drain regions 58 and 60 of the P-typethin film transistor while there is no much difference in crystallinity.

There is no great difference in crystallinity between the two regions inthe step shown in FIG. 9(C) because the source/drain regions 58 and 60of the P-channel type thin film transistor are not greatly damaged bythe ion implantation.

Thus, in case of annealing the source/drain regions of the two thin filmtransistors by irradiating a laser light in the state shown in FIG.9(D), the difference in annealing effect can be corrected. That is, thedifference in characteristics can be corrected for the N- and P-channeltype thin film transistors.

Once a stage as shown in FIG. 9(D) is obtained, a 4,000-Å-thickinterlayer insulating film 62 is formed as is shown in FIG. 10(A). Theinterlayer insulating film 62 may be a silicon oxide film, a siliconoxynitride film, or a silicon nitride film. Otherwise, it may have amultilayered structure. The silicide films can be formed by means ofplasma CVD or thermal CVD.

Then, after forming contact holes, a source electrode 63 and a drainelectrode 64 for the N-channel thin film transistor (NTFT) are formed. Asource electrode 65 and a drain electrode 66 for the P-channel thin filmtransistor (PTFT) are also formed simultaneously (FIG. 10(B)).

Patterning is performed thereafter in such a manner that the drainelectrode 64 of the N-channel type thin film transistor may be connectedwith the drain electrode 66 of the P-channel type thin film transistor.By further connecting the gate electrodes of two TFTs with each other, aCMOS structure can be implemented.

A thin film circuit of a CMOS type as in the present embodiment can beemployed in an active matrix type liquid crystal display device and anactive matrix type EL display device.

In the impurity ion implantation steps shown in FIGS. 8(E), 9(B), and9(C), it is important that the active layer is covered by a siliconoxide film 35 constituting the gate insulating film.

By performing implantation of impurity ions in this state, surfaceroughening and contamination of the active layer can be suppressed. Thisgreatly contributes to an increase in production yield and inreliability of the device.

EMBODIMENT 7

The present embodiment refers to a constitution in which the crystallinesilicon film described in Embodiment 1 is formed on a silicon wafer. Itis necessary to provide an insulating layer on the surface of thesilicon wafer, and, in general, a thermal oxidation film is usedtherefor.

The heat treatment is generally conducted in a temperature range of from700 to 1,300° C., and the period of time for the treatment variesdepending on the desired oxide film thickness.

The thermal oxidation of a silicon wafer is generally performed under anatmosphere of O₂, O₂ --H₂ O, H₂ O, or combusted O₂ --H₂. Oxidation underan atmosphere into which a halogen element such as HCl or Cl₂ is addedis also put widely into practice.

A silicon wafer is one of the substrates indispensable for asemiconductor device such as an IC. Various techniques for forming avariety of semiconductor elements on the wafer have been developed.

By utilizing the present embodiment, the application range of acrystalline silicon film can be further extended by combining thecrystalline silicon film having a crystallinity well equivalent to thatof a single crystal with a conventional technique using silicon wafers.

EMBODIMENT 8

The present embodiment refers to a specific constitution with referenceto Embodiment 7, in which a TFT utilizing the crystalline silicon filmaccording to the present invention is formed on an IC being formed on asilicon wafer. The manufacturing process is described schematically withreference to FIGS. 11(A) to 11(D).

FIG. 11(A) shows a MOS-FET formed on a silicon wafer by an ordinaryprocess. It comprises a silicon substrate 71, and insulating films 72and 73, which are generally thermally oxidized films, for isolating theelements from each other. A source region 74 and a drain region 75 areformed by diffusion process after implanting impurity ions into thesilicon substrate 71 to render it conductive. Thus, in case the siliconsubstrate 71 is P-type, an impurity for rendering it N-type conductive,i.e., phosphorus, is implanted. Reversely, if the silicon substrate 71is N-type, an impurity for rendering it P-type conductive, i.e., boron,is implanted.

The region 76 is a channel forming region. In this region, a part of thethermal oxidation film that is formed in the diffusion process after theion implantation is left over on the surface of silicon by controllingthe film thickness, so that it may function as a gate insulating film. Apolycrystalline silicon film having a single conductive type is used fora gate electrode 77.

The gate electrode 77 is covered by an insulating film 78 such assilicon oxide film in such a constitution that it may not form anelectric short circuit with the source electrode 79 and the drainelectrode 80 (FIG. 11(A)).

After the state shown in FIG. 11(A) is obtained, an interlayerinsulating film 81 is formed. A silicon oxide film, a silicon nitridefilm, etc., is used for the interlayer insulating film. After formingthe interlayer insulating film 81, a contact hole is formed to provide atake out wiring 82 to the drain electrode (FIG. 11(B)).

Then, polishing is effected after the state shown in FIG. 11(B) isobtained. That is, the exposed surface is planarized by means of CMP(chemical mechanical polishing) technique. Thus is obtained a planarizedinterlayer insulating film 81, and the convex portion of the take outwiring 82 is removed.

In FIG. 11(C), a planarized surface 84 is provided on the planarizedinterlayer insulating film 83. A convex portion is no longer observed ontake out wiring 85, and another take out wiring 86 is formed inconnection therewith.

An interlayer insulating film 87 is formed thereafter. The presentinvention is applicable to the interlayer insulating film 87. That is, athin film transistor using the monodomain region for the active layer isformed on the interlayer insulating film 87.

Firstly, in accordance with Embodiment 1, an active layer 88 is formedby using the monodomain region. A gate insulating film 89 is formedthereafter, and a gate electrode 90 is formed subsequent thereto. Then,an impurity for imparting a single conductive type to the active layeris implanted.

After completion of the impurity implantation, a side wall 91 is formedto provide a low density impurity region in the later steps. A side wall91 can be formed as follows.

By using a silicon oxide film and the like, an insulating film (notshown in the figure) which covers the gate electrode 90 is formed to athickness not less than the film thickness of the gate electrode 90.Then, anisotropic etching is effected by means of dry etching to removethe thus deposited insulating film. Thus, the insulating film remainsonly on the side surfaces of the gate electrode 90 to provide a sidewall 91.

Impurity implantation is performed again in this state. The regionsimplanted with an impurity in the second time become a source region anda drain region, and the region shielded with the side wall 91 providesan impurity region containing the impurity at a density lower than thatin the source and drain regions. The impurity thus incorporated isactivated thereafter by, for example, applying heat treatment orirradiating a laser light.

In the manner above, a silicon oxide film or a silicon nitride film isformed as an interlayer insulating film 92 after the active layer isconstructed. Then, after forming contact holes, a source electrode 93and a drain electrode 94 are also formed.

As is described in the present embodiment, an integrated circuit havinga three-dimensional structure as is illustrated in FIG. 11(D) can beimplemented by applying the present invention to an IC. Because the TFTformed on the upper side of the IC according to the present inventionyields a performance well equivalent to that of a TFT formed on a singlecrystal, the performance of the original IC remains without beingimpaired so as to make it feasible an integrated circuit at a everhigher integration density.

EMBODIMENT 9

The present embodiment refers to a constitution in which a TFTmanufactured by applying the present invention is employed in a DRAM(dynamic random access memory). The explanation is made with referenceto FIGS. 12(A) and 12(B).

A DRAM is a memory in which the information to be recorded is stored asa charge in a capacitor. The pieces of information in the form ofcharges are input and output into the capacitor under control of a TTserial connected to the capacitor. The circuit comprising a TFT and acapacitor which constitutes a single memory cell of a DRAM is shown inFIG. 12(A).

When a gate signal is provided through a word line 1201, the TFT 1203assumes a conducting state. In this state, the capacitor 1204 is chargedfrom the bit line 1202 side to write information, or the chargedcapacitor is discharged to read information.

The cross section structure of a DRAM is shown in FIG. 12(B). A basebody 1205 is made of a quartz substrate or a silicon substrate. Aso-called SOI structure can be implemented if a silicon substrate isused.

A silicon oxide film 1206 is formed as a base film on the base body1205, and a TFT is formed thereon by applying the present invention. Ifthe base body 1205 is a silicon substrate, a thermal oxidation film canbe used as the base film 1206. An active layer 1207 consisting of amonodomain region formed in accordance with Embodiment 1 is alsoprovided.

The active layer 1207 is covered by a gate insulating film 1208, and agate electrode 1209 is formed thereon. After laminating an interlayerinsulating film 1210 thereon, a source electrode 1211 is formed. A bitline 1202 and an electrode 1212 are formed simultaneously with theformation of the source electrode 1211. A protective film 1213comprising an insulating film is also provided.

The electrode 1212 maintains a fixed potential to thereby form acapacitor 1214 between the electrode 1212 and the drain region of theactive layer located below the electrode 1212. That is, the memoryelement functions by writing or reading out the charge accumulated inthe capacitor by a TFT.

A DRAM is characterized in that a single memory can be implemented byextremely few number or elements, i.e., a TFT and a capacitor. Thus, itis suitable for constructing a large scale memory with high integrationdensity. Moreover, it is utilized in largest quantity at present becausethe price thereof can be suppressed to a low level.

For instance, in case an SOI structure is formed on a silicon substrateby applying the present invention, the leak current of the TFT can beminimized, because the junction area is small. This greatly contributesto the duration time of data retention.

Furthermore, a DRAM cell formed on a SOI substrate is also characterizedin that it enables operation at a low voltage, because the capacity canbe set at a low value.

EMBODIMENT 10

The present embodiment refers to a constitution in which a TFTmanufactured by applying the present invention is employed in a SRAM(static random access memory). The explanation is made with reference toFIGS. 13(A) and 13(B).

A SRAM is a memory which utilizes a bistable circuit such as a flip-flopfor the memory element, and binary information values (0 or 1) arerecorded in correspondence with the bistable states, i.e., ON-OFF orOFF-ON, of the bistable circuit. This memory is advantageous in that itretains the memory so long as an electric power is supplied.

The memory circuit is constructed by an N-MOS or a C-MOS. The SRAM shownin FIG. 13(A) is a circuit comprising a high resistance for the passiveload element.

A word line 1301 and a bit line 1302 are provided in the constitution. Aload element 1303 is constructed from a high resistance. Two pairs ofdriver transistors 1304 and two pairs of access transistors 1305constitute the SRAM.

The cross section structure of the TFT is shown in FIG. 13(B). Asubstrate 1306 is made of a quartz substrate or a silicon substrate. Asilicon oxide film 1307 is formed as a base film on the substrate 1306,and a TFT is formed thereon by applying the present invention. An activelayer 1308 consisting of a monodomain region formed in accordance withEmbodiment 1 is also provided.

The active layer 1308 is covered by a gate insulating film 1309, and agate electrode 1310 is formed thereon. After laminating an interlayerinsulating film 1311 thereon, a source electrode 1312 is formed. A bitline 1302 and a drain electrode 1313 are formed simultaneously with theformation of the source electrode 1312.

An interlayer insulating film 1314 is formed again on the structure, anda polysilicon film 1315 is formed as a high resistance load. Aprotective film 1316 comprising an insulating film is also provided.

The SRAM obtained with the constitution above is capable of high speedoperation, is highly reliable, and can be readily embedded into systems.

EMBODIMENT 11

The present embodiment refers to a constitution in which an activematrix region and a peripheral drive circuit for driving the activematrix region are integrated on a same based body by using asemiconductor device according to Embodiment 3 and a CMOS structuredescribed in Embodiment 6.

One base body constituting an integrated liquid crystal display deviceof an active matrix type is constructed as follows. More specifically,in the active matrix region, at least one thin film transistor forswitching is provided to each of the pixels arranged in a matrix, and aperipheral circuit for driving the active matrix region is provided inthe periphery of the active matrix region. These circuits are allintegrated on a single glass substrate (or a quartz substrate or asilicon substrate).

By applying the present invention to the constitution above, an activematrix region and a peripheral circuit can be constructed by a thin filmtransistor having a performance well equivalent to that of a MOS-FETformed on a single crystal.

That is, the pixel TFT for the active matrix region is constructed witha thin film transistor shown in FIG. 4(E) while constructing theperipheral circuit with a CMOS constitution shown in FIGS. 8 to 10.

It is desired that the OFF current value of the thin film transistorprovided to the active matrix region is suppressed as low as possiblebecause the charge retained in the pixel electrode must be held for apredetermined duration time of time.

Because the thin film transistor according to the present inventioncomprises an active layer consisting of a monodomain region, there issubstantially no grain boundary that provides a path (current path)through which the off current flows preferentially. Accordingly, a thinfilm transistor having a small OFF current can be provided.

On the other hand, CMOS circuits are widely used for the peripheraldrive circuit. To obtain a CMOS circuit with high performance, thecharacteristics of the N-channel type and P-channel type transistorsconstituting the CMOS circuit must be made uniform as much as possible.

A CMOS structure described in Embodiment 6 with reference to FIGS. 8 to10 is most suitable for achieving the above object.

An integrated active matrix type liquid crystal device can be thusimplemented by a constitution comprising circuits each provided with themost favorable characteristics.

EMBODIMENT 12

The present invention refers to a constitution similar to that describedin Embodiment 3, except that the gate insulating film is formed in adifferent step.

First, a thin film semiconductor comprising the monodomain region isformed through a process similar to that described in Embodiment 1, andan active layer for the semiconductor device is formed by selectivelyutilizing the monodomain region alone.

Then, an insulating film (a silicon oxide film in the presentembodiment) containing silicon as a main component thereof is formed bymeans of a vapor phase process represented by a CVD or a PVD process ata thickness of from 200 to 1,500 Å (800 Å in the present embodiment), insuch a manner that it covers the active layer. The film thickness of thesilicon oxide film is determined by taking the final withstandinsulating voltage into consideration. A silicon oxynitride film or asilicon nitride film may be used in the place of the silicon oxide film.

Heat treatment in an atmosphere containing a halogen element isperformed upon completion of the formation of the silicon oxide film.The main object of the heat treatment is to remove the metal residues,such as nickel, remaining inside the active layer by gettering. The heattreatment may be performed in a temperature range of from 600 to 1,100°C., but to sufficiently obtain the effect of gettering, it is preferablyconducted at a temperature exceeding 700° C. (preferably in a range of800 to 1,000° C.).

In case a glass substrate is used as the substrate, the heat treatmentabove must be performed in a temperature range of 600 to 650° C. bytaking the heat resistance of the substrate into consideration. In casea material having high heat resistance is used for the substrate, suchas a quartz substrate, the upper limit of the heating temperature can beelevated to about 1,100° C. (preferably 1,000° C.).

In the present embodiment, the heat treatment is effected on a quartzsubstrate and in a gaseous oxygen atmosphere into which 0.5 to 10% (3%in the present embodiment) of hydrogen chloride (HCl) is added. If theconcentration of HCl should be higher than the range above, the surfaceof the crystalline silicon film will be roughened. In the presentembodiment, the heat treatment is performed at a temperature of 950° C.for 0.5 hours.

To prepare an atmosphere containing a halogen element, at least one or aplurality of gaseous elements selected from the group consisting of HCl,HF, HBr, Cl₂, NF₃, F₂, and Br₂ are added into an oxygen atmosphere.

As a result of the step above, the gettering function of the halogenelement works on the metallic element, and the nickel concentrationinside the active layer is thus lowered by gettering to a level of1×10¹⁷ atoms/cm³ or lower (preferably 1×10¹⁶ atoms/cm³ or lower, andmore preferably, at a spin density or lower). The above concentration isan observed value obtained by SIMS (secondary ion mass spectroscopy).

A thermal oxidation reaction proceeds and a thermal oxide film about 200Å in thickness is formed thereby at the interface between the activelayer and the silicon oxide film. The OFF current can be effectivelylowered by setting the final film thickness of the active layer to be ina range of 200 to 300 Å (representatively 250 Å).

In the present embodiment, an additional heat treatment is performedunder a gaseous nitrogen atmosphere at 950° C. for 1 hour is effectedafter the above heat treatment using an atmosphere containing a halogenelement. In this manner, the film quality of the thermal oxidation filmand the insulating film containing silicon is improved.

Nickel is believed to be segregated in the grain boundary of thecrystalline silicon film constituting the active layer. Thus, aplurality of dangling bonds generate by removing nickel therefrom. Theplurality of dangling bonds undergo recombination by the heat treatmentat 950° C. to form a grain boundary reduced in the density of traplevels.

As a result of the heat treatment performed in an atmosphere containinga halogen element, residual halogen element remains at a highconcentration in the vicinity of the interface between the active layerand the gate insulating film. According to the results of SIMS, halogenelements remain at a concentration of 1×10¹⁹ to 1×10²⁰ atoms/cm³.

The thermal oxidation film formed at the interface between the activelayer and the silicon oxide film above constitute the gate insulatingfilm together with the aforementioned silicon oxide film. Because thedefect levels, the interlattice silicon atoms, etc., are reduced at theinterface of the active layer, an extremely superior interface state isobtained at the interface between the active layer and the gateinsulating film.

As described above, the concentration of metallic elements such asnickel can be lowered by performing the heat treatment according to thepresent embodiment. From the viewpoint of improving the reliability of asemiconductor device, it is very important for a semiconductor device toreduce the concentration of a metallic element such as nickel. A gateinsulating film having a favorable interface state can be formed byimproving the crystalline state of the active layer.

As described above, a semiconductor device having excellent electricproperties and a high reliability can be implemented.

EMBODIMENT 13

The present invention refers to a constitution in which the interfacestate between the active layer and the gate insulating film is improved.In particular, the present technique is effective in case a glasssubstrate is used.

First, a thin film semiconductor comprising the monodomain region isformed through a process similar to that described in Embodiment 1, andan active layer for the semiconductor device is formed by selectivelyutilizing the monodomain region alone. Then, in the same manner as inEmbodiment 12, a silicon oxide film is formed by means of CVD or PVDprocess at a thickness of from 200 to 1,500 Å.

Heat treatment is then performed in a temperature range of from 500 to700° C. (representatively, at 640 to 650° C.). This temperature range isset so that a thermal oxide film can be formed without generating anydeformation or warping on the glass substrate. The heat treatment may beperformed in an atmosphere containing oxygen alone, or in an atmospherecontaining a halogen atom. It is also possible to use a wet atmospherecontaining water vapor.

In case of performing a heat treatment under the conditions of thepresent embodiment, a thermal oxidation film less than several tens ofangstroms (Å), for instance, 10 to 90 Å, can be formed by applying thetreatment for a duration of about 0.5 to 2 hours. The growth of thethermal oxidation film does not proceed any more after the filmthickness attains the saturated value above.

According to the knowledge of the present inventors, fixed charges, thedensity of defect levels, etc., concentrate in the very vicinity of theinterface between the active layer and the gate insulating film (i.e., aregion about 10 to 30 Å in length as measured from the interface to theactive layer side and the gate insulating film side). Accordingly, itcannot be exaggerated that this region determines the interface statebetween the active layer and the gate insulating film.

Thus, to attain a favorable state at the interface between the activelayer and the gate insulating film, it is necessary to only remove thefixed charges, the density of defect levels, etc., by thermallyoxidizing merely the region of 10 to 30 Å in width at the interface ofthe active layer (the thickness of the active layer reduces by 10 to 30Å, while newly developing a 20 to 60 Å thick thermal oxidation film). Inother words, a favorable interface state can be realized by merelyforming a thermal oxidation film less than about several tens ofangstroms (Å) in thickness.

By thus incorporating the thermal oxidation step of the presentembodiment, a semiconductor device having an excellent performance canbe manufactured on a substrate having a poor heat resistance, such as aglass substrate.

EMBODIMENT 14

The present embodiment refers to a constitution in which a crystallinesilicon film (polysilicon film) is used as the gate electrode. Theexplanation is made with reference to FIGS. 15(A) to 15(D).

Referring to FIG. 15(A), the structure comprises a glass substrate 1501,a base film 1502, an active layer 1503 comprising a monodomain regionobtained by the process described in Embodiment 1, a gate insulatingfilm 1504, and a gate electrode 1505 comprising a polysilicon filmimparted with a monoconductive type.

Then, impurity ions for imparting a monoconductive type to the activelayer 1503 are imparted. Impurity regions 1506 and 1507 are formed bythe impurity implantation step in this manner.

Upon the completion of the implantation of impurity ions, a 0.5 to 1 μmthick silicon nitride film 1508 is formed. The film can be formed by anymethod selected from low pressure thermal CVD, plasma CVD, andsputtering. A silicon oxide film can be used instead of the siliconnitride film.

Thus is obtained a state as is shown in FIG. 15(B). Once the stateillustrated in FIG. 15(B) is obtained, the silicon nitride film 1508 isetched by means of etchback process to leave over only the side walls ofthe gate electrode 1505. The silicon nitride film thus left overfunctions as a side wall 1509.

A state as is shown in FIG. 15(C) is thus realized by removing the gateinsulating film 1504 except for the region for which the gate electrode1505 and the side wall 1509 functioned as a mask.

Impurity ions are implanted thereafter to a state as is shown in FIG.15(C). In this case, the dose is set at a value higher than that of theprevious ion implantation. Because ion implantation is not performed onthe regions 1510 and 1511 just under the side wall 1509, theconcentration of the impurity ions remain the same. However, the exposedregions 1512 and 1513 are implanted further heavily with the impurityions.

By thus performing the ion implantation twice, lightly doped drainregions (LDD regions) 1510 and 1511 containing the impurity ions at animpurity concentration lower than that of the source region 1512, drainregion 1513, and source/drain region can be formed. The region justunder the gate electrode 1505 is an undoped region, and provides achannel forming region 1514.

After obtaining a state as is shown in FIG. 15(C) as a result of theabove-mentioned process steps, a 300-Å-thick titanium film not shown inthe figure is formed, and is allowed to react with the silicon film.Then, after removing the titanium film, a heat treatment such as lampannealing is performed to form titanium silicide films 1515 to 1517 onthe exposed surface of the source region 1512, drain region 1513 andgate electrode 1505(FIG. 15(D)).

A tantalum film, a tungsten film, a molybdenum film, etc., can be usedin place of titanium film mentioned above.

A 5,000-Å-thick silicon oxide film is then formed as an interlayerinsulating film 1518, and a source wiring 1519, drain wiring 1520, and agate wiring 1521. A TFT having a structure as is shown in FIG. 15(D) isthus completed.

In the TFT of the structure according to the present embodiment, thewiring is connected to the TFT via the titanium silicide films 1515 to1517. Accordingly, a favorable ohmic contact can be implemented.

EMBODIMENT 15

The semiconductor device as referred herein signifies a device whichfunctions by using a semiconductor, and it includes an active matrixtype electro-optical device (a liquid crystal display device, an ELdisplay device, an EC display device, etc.) of the constitutiondescribed in Embodiment 11, and an application product into which theelectro-optical device is embedded.

In the present embodiment, the application products are explained withreference to figures. Semiconductor device utilizing the presentinvention include a TV camera, a head mount display, a car navigationsystem, a projection type display (inclusive of a front type and a reartype), a video camera, a personal computer, etc. Brief explanation isgiven below with reference to FIGS. 16(A) to 16(F).

FIG. 16(A) shows a mobile computer comprising a body 2001, a camera2002. an image receiver 2003, an operation switch 2004, and a displaydevice 2005. The present invention is applied to, for example, thedisplay device 2005 or an integrated circuit embedded inside the device.

FIG. 16(B) shows a head mount display comprising a body 2101, a displaydevice 2102, and a band portion 2103. Two relatively compact displaydevices 2102 are used.

In FIG. 16(C) is shown a car navigation system comprising a body 2201, adisplay device 2202, an operation switch 2203, and an antenna 2204. Thepresent invention is applied to, for example, the display device 2202 oran integrated circuit embedded inside the device. The display device2202 is used as a monitor, but because it is used for displaying a map,the allowable range of image resolution is relatively wide.

FIG. 16(D) is a portable phone comprising a body 2301, a voice outputportion 2302, a voice input portion 2303, a display device 2304, anoperation switch 2305, and an antenna 2306. The present invention isapplied to, for example, the display device 2304 or an integratedcircuit embedded inside the device.

In FIG. 16(E) is shown a video camera comprising a body 2401, a displaydevice 2402, a voice input portion 2403, an operation switch 2404, abattery 2405, and an image receiver 2406. The present invention isapplied to, for example, the display device 2402 or an integratedcircuit embedded inside the device.

FIG. 16(F) is a front-type projection display comprising a body 2501, alight source 2502, a reflection type display device 2503, an opticalsystem (inclusive of a beam splitter and a polarizer) 2504, and a screen2505. Because the screen 2505 is used as a large area display for thepresentation in a conference or a meeting, a high image resolution isrequired to the display device 2503.

In addition to the electro-optical devices described above, the presentinvention is applicable to, for example, a rear-type projection displayor portable information terminal equipments such as a handy terminal. Asis described above. the application range of the present invention iswide, and the present invention is applicable to any type of displaymedia in various fields.

As is described hereinbefore, the present invention is characterized inthat the crystal grain diameter is controlled by intentionally formingnucleation sites. The present invention is also characterized in thatthe crystal grains thus formed at a relatively large diameter areconverted into a single crystal by irradiating a laser light and thelike.

As an effect of the present technique, a monodomain region which can beregarded as substantially a single crystal is realized on a substratehaving an insulating film on the surface thereof. That is, an activelayer of a semiconductor device such as a thin film transistor can beconstructed by using a crystalline silicon film having a highcrystallinity well equivalent to that of a single crystal.

Thus, a semiconductor circuit having a performance well equivalent tothat of a known integrated circuit using a single crystal wafer can beimplemented.

While the invention has been described in detail and with reference tospecific embodiments thereof, it will be apparent to one skilled in theart that various changes and modifications can be made therein withoutdeparting from the spirit and scope thereof.

What is claimed:
 1. A method for manufacturing a semiconductor deviceincluding an active layer comprising a semiconductor film, said methodcomprising:forming a silicon oxide film on an insulating surface;forming at least a concave or convex pattern by patterning said siliconoxide film into a shape; forming an amorphous semiconductor film on saidsilicon oxide film forming a catalytic material in contact with saidamorphous semiconductor film, said catalytic material being capable ofpromoting crystallization of said amorphous semiconductor film;crystallizing said amorphous semiconductor film into a crystallinesemiconductor film by heating; and irradiating said crystallinesemiconductor film with a light to modify said crystalline semiconductorfilm into a monodomain region.
 2. A method according to claim 1 whereinsaid crystalline semiconductor film is formed by a plurality of columnaror needle-like crystals which grow in a parallel direction to saidinsulating surface.
 3. A method according to claim 1 wherein saidsilicon oxide film is formed by sputtering using an artificial quartztarget.
 4. A method according to claim 1 wherein said catalytic materialcomprises at least a material selected from the group consisting of Fe,Co, Ni, Ru, Rh, Pd, Os, Ir, Pt, Cu, and Au.
 5. A method according toclaim 1 wherein said active layer is formed by only said monodomainregion.
 6. A method according to claim 2 wherein said monodomain regionis formed by aggregating said plurality of columnar or needle-likecrystals in said irradiating step.
 7. A method according to claim 1wherein said monodomain region is regarded as a single crystal.
 8. Amethod according to claim 1 wherein said monodomain region includes nocrystal grain boundary.
 9. A method according to claim 1 wherein saidsemiconductor device is a thin film transistor.
 10. A method accordingto claim 1 wherein said monodomain region has a film thickness of 150 to450 Å.
 11. A method according to claim 1 wherein an outer portion ofsaid monodomain region is made convex by irradiating with said light.12. A method according to claim 1 wherein a film thickness of an outerportion of said monodomain region is greater than that of the monodomainregion.
 13. A method according to claim 1 wherein hydrogen is added intosaid semiconductor film at a concentration of 1×10¹⁵ to 1×10²¹atoms/cm³.
 14. A method according to claim 1 wherein said monodomainregion comprises:a first region being a vertical growth region on saidconcave or convex pattern; and a second region being a lateral growthregion obtained by crystal growth initiated from said vertical growthregion and grown in a direction parallel to a surface of saidsemiconductor film, wherein said vertical growth region includes saidcatalytic material at a concentration higher than that in said lateralgrowth region.
 15. A method of manufacturing a semiconductor devicehaving an active layer including a semiconductor film, said methodcomprising the steps of:forming a silicon oxide film by sputtering on aninsulating surface; forming at least a concave or convex pattern bypatterning said silicon oxide film into a shape; forming an amorphoussemiconductor film on said silicon oxide film; forming a catalyticmaterial element in contact with said amorphous semiconductor film, saidcatalytic material being capable of promoting crystallization of saidamorphous semiconductor film; crystallizing said amorphous silicon filminto a crystalline semiconductor film by heating; irradiating saidcrystalline semiconductor film with a light to modify said crystallinesemiconductor film into a monodomain region; forming an active layer byusing only said monodomain region; forming an insulating film coveringsaid active layer, said insulating film comprising silicon; heating saidactive layer in an atmosphere including a halogen element for getteringand removing said catalytic material and forming a thermal oxide film atan interface between said active layer and said insulating film; andheating said insulating film under a nitrogen atmosphere to improve aquality of said insulating film and said thermal oxide film.
 16. Amethod according to claim 15 wherein said crystalline semiconductor filmis formed by a plurality of columnar or needle-like crystals which growin a parallel direction to said insulating surface.
 17. A methodaccording to claim 15 wherein said silicon oxide film is formed bysputtering using an artificial quartz target.
 18. A method according toclaim 15 wherein said catalytic material comprises at least a materialselected from the group consisting of Fe, Co, Ni, Ru, Rh, Pd, Os, Ir,Pt, Cu, and Au.
 19. A method according to claim 15 wherein said activelayer is formed by only said monodomain region.
 20. A method accordingto claim 16 wherein said monodomain region is formed by aggregating saidplurality of columnar or needle-like crystals in said irradiating step.21. A method according to claim 16 wherein said monodomain region isregarded as a single crystal.
 22. A method according to claim 16 whereinsaid monodomain region includes no crystal grain boundary.
 23. A methodaccording to claim 16 wherein said semiconductor device is a thin filmtransistor.
 24. A method according to claim 16 wherein said monodomainregion has a film thickness of 150 to 450 Å.
 25. A method according toclaim 16 wherein an outer portion of said monodomain region is madeconvex by irradiating with said light.
 26. A method according to claim16 wherein a film thickness of an outer portion of said monodomainregion is greater than that of the monodomain region.
 27. A methodaccording to claim 16 wherein hydrogen is added into said semiconductorfilm at a concentration of 1×10¹⁵ to 1×10²¹ atoms/cm³.
 28. A methodaccording to claim 16 wherein said monodomain region comprises:a firstregion being a vertical growth region on said concave or convex pattern;and a second region being a lateral growth region obtained by crystalgrowth initiated from said vertical growth region and grown in adirection parallel to a surface of said semiconductor film, wherein saidvertical growth region includes said catalytic material at aconcentration higher than that in said lateral growth region.
 29. Amethod according to claim 16 wherein,said insulating film and saidthermal oxide film functions as a gate insulating film, and a halogenelement is present at a high concentration in the vicinity of aninterface between said active layer and said gate insulating film.
 30. Amethod for fabricating a semiconductor device having an active layerincluding a semiconductor film on an insulating film formed on an upperside of active circuits being integrated on a semiconductor substrate,said method comprising:forming at least a concave or a convex pattern onsaid insulating film; forming a semiconductor film in contact with anupper surface of said insulating film; forming a catalytic materialbeing capable of promoting crystallization of said semiconductor film incontact with said semiconductor film; crystallizing said semiconductorfilm to form a plurality of columnar or needle-like crystals which growin parallel with said substrate therein; irradiating said semiconductorfilm with a light to aggregate said plurality of columnar or needle-likecrystals to form a monodomain region, said monodomain region includingno crystal grain boundary, and patterning said monodomain region to formsaid active layer.
 31. A method for manufacturing a semiconductor deviceincluding an active layer comprising a semiconductor film, said methodcomprising:forming a silicon oxide film on an insulating surface;forming at least a concave or convex portion by patterning said siliconoxide film into a shape; forming an amorphous semiconductor film on saidsilicon oxide film; and crystallizing said amorphous semiconductor filminto a crystalline semiconductor film, wherein said crystallizing ofsaid amorphous semiconductor film proceeds starting at said concave orconvex portion.
 32. A method according to claim 31 wherein saidamorphous semiconductor film is crystallized by heating.
 33. A methodfor manufacturing a semiconductor device including an active layercomprising a semiconductor film, said method comprising:forming at leasta concave or convex shaped portion over a substrate; forming anamorphous semiconductor film over said substrate; and crystallizing saidamorphous semiconductor film into a crystalline semiconductor film;wherein the crystallizing said amorphous semiconductor film proceedsstarting at said concave or convex portion.